Metal-founding.



C. B. CARTER.

METAL FOUNDING.

APPLICATION FILED AUG. 24, 1910.

Patented Oct. 25, 1910.

2 SHBETS-SHEET l.

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dlm d N G. B. CARTER.

METAL FOUNDING.

' APPLIOATION FILED AUG. 24, I910.

Patented Oct. 25, 1910.

2 SHEETS-BEEET 2.

m m m 7, m 7 M 1 z W the mold in such the casting, is at UNITED STATESPATENT onrron.

cameras is. can-ran, or CHICAGO, ILLINOIS.

Specification of Letters Batent.

Patented Oct. 25, 1910.

Application filed August 24, 1910. Serial No; 578,800.

To all whom it may concern.

Be it known that I, CHARLES B. CARTER, a cltlzen of the United States,and a resident of chicago in the county of Cook and State of Illinois,have invented certain new. and

useful Improvements in the Art of Metal- Founding, fication.

This invention of which the following is a specirelates to improvementsin the art of metal founding, and has particularly in view an improvedmanner of and apparatus for holding in position in the mold the metalinserts placed there, in order that they may be incorporated in thecasting subsequently formed therein.

It also has in view animproved manner of clamping the mold togetherpreparatory.

to pouring, which latter improvement may be found useful even whenmetallic inserts are not used in the mold.

In casting brake shoes, for example, it is common practice to place anumber of pieces or bars of relatively hard or tough metal in positionthat when the brake shoe is subsequently cast, these pieces or bars willbecome incorporated in the face of the brake shoe, as so-called inserts,by which the wearing and braking qualities and life of the shoe will begreatly increased. Steel backing pieces are also inserted in brake shoemolds will. become incorporated with the shoe on its backside, much asthe metal inserts above mentioned become incor orated in its face. Thisis particularly t e case with brake shoes designed for use on the drivewheels of locomotives, in which case the backing iece or back, which isusually made of SE the lug by which the shoe is keyed in place suchinserts in the brake head. or backing ieces are employe however, theproblem 0 securing them at the proper points in the mold preparatory topouring When an quently found desirable to cast the shoe face upwardly,and in such case the inserts must be secured in the top of the moldcavity and suspended, as -it were, from the top wallor roof of the mold.Or, if the casting rangement is reversed and the shoe is cast with itsface downward, the steel back, when used, must be similarly secured orsusper part of the. ,mold cavity and held in p ace against the 1 pended,as itwere, inv the u sweep them out ample as will be set up in suchposition that they once presented. It is freplace during the pouringoperation, since the inrushaof the entering metal is liable to ofposition unless securely held With these facts in view, ventioncontemplates the employment of magnetic attraction, to hold in properposition within the mold any such inserted my present inpieces-backs,face inserts, or the like. The

magnetism utilized. may be inherent in the parts themselves, or may bedue to a properlyc applied magnetic field, such for exby anelectromagnet that can be controlled at will by re lating the currentthrough its coils, which will operate to draw the inserted places. (ofiron or steel) firmly toward or against the adjacent inner surfaces ofthe mold, force sufiicient to overcome the attraction of gravitation andto successfully resist any with a tendency of the inflowing metal towash the inserted pieces out of place. This improve- -mentthe employmentof magnetic attraction to hold the inserted pieces in place in themold-may vantage in connection with the casting of brake shoesinmetallic molds or chills, Where the mold itself is made wholly orrincipally of magnetizable metal and is ormed to permanently present theshape of cavity desired for the shoe. With such metal molds, the problemof holding the inserted pieces securely'in position prior'to and duringthe pouring of metal, is quite a serious one, particularlywhere it isnecessary to suspend, as it were, the insert pieces from the roof of themold cavity, butthe problem is readily solved by resorting 'to magnetica-ttraction, in accordance with the contemplation of this improvement.For example, the inserts in th-is case may be made of steel and firstpermanently magnetized, so that they will inherently tend to fastenthemselves to the surface of the iron mold at whatever he used toparticular adpoint where they are placed in contact with I it. Orassuming again, for example, that it 'is desired to cast a brake shoewith its face uppermost and with iron or steel inserts 1nthe face of theshoe, an electromagnet may be provided, in connection with the mold, insuch manner as to draw the inserted pieces firmly against the roof ofthe mold cavity and hold them securely in place there until the metalhas been poured in and has solidified about the inserts sufficiently tohold them permanently in position, the magits bottom, the magneticaction, however,

serving as before to hold the inserted parts.

securely in place until the casting is completed. Furthermore, with amold constructed principally or largely of iron, the

I same magnetic action may be utilized to clamp the parts of the molditself together thus doing away with the mechanical clamps ordinarilyused for the purpose. And this method of clamping together the parts orsections of a mold which is formed wholly or largely of iron or steel,or has sufficient iron or steel parts incorporated in its differentsections, may obviously be found of advantage without regard to whetheror not the magnetic action is also utilized for the positioning withinthe mold of inserted metallic pices, such as backs or faces. All of thisis illustrated, by the way of example, in the accompanying drawin s, inwhich Figure l is a longitudina section, taken on line 1 1 of Fi 2, of ametallic mold provided with an e ectromagnet attachment and arranged forthe casting of brake shoes with a steel back and face inserts. Fig.2 isa transverse sectional view thereof, taken on the line 2-2 of Fig. 1.Fig. 3 is a perin this instance,

spective view of a brake shoe, such as is designed to be cast in thismold. Fig. at is an' enlarged perspective detail ofa sectional metalliccore piece designed for the coring of the hole through the lug on theback of the shoe, by which the shoe is attached to the 5 is alongitudinal'section, taken on the line 55 of Fig. 6, of a generallysimilar mold in which, however, the electromagnet arrangement issomewhat dif ferent, and from which the steel back has,

' been omitted. -Fig. 6 is a transverse section of this mold taken onthe line 6-6 of Fig. 5. Fig. 7 is a' perspective view of such a brakeshoe as is designed to be cast in this mold. Fig. 8 is a perspectivedetail of a'sectional metallic core piece, slightly modified from thatshown in Fig. &.

Referring first to the construction shown in Figs. 1 and 2, it will beunderstood that the mold here illustrated is a two-part affair,

If a steel consistin as usual of a drag land cope 2. The mol is partedon the line 3 and is provided with suitable sprue holes t through whichthe pouring may take place. This mold is shown as arranged for thecasting of shoes face upward, and with iron or steel inserts 5 in theface of the shoe, and it is contemplated that these inserts will be heldin place within the mold cavity 6 preparatory to and during the castingoperation, by magnetic action, such as will serve to make the insertsstick, as it were, to the upper surface of the mold cavity-the lowerface of the cope.until the metal has had time to cool and solidifyaround them so as to hold them permanently in position. Assuming thatthese inserts are made of steel, they may be permanently magnetizedbefore being used, and in such case the magnetic attrac- I tion inherentin them will serve to make them stick wherever placed against the undersurface of the cope, where this is made of iron or steel, withsufficient tenacity to enable the casting to be poured, without theirdropping off or being otherwise dis turbed in their positions. Or themagnetic action will be brought about by an electromagnet such as I-have illustrated, somewhat diagrammatically, at 7 The coreB of thismagnet I have shown as terminating at its lower end in a pole plate 9that is arranged to fit against the upper surface of the cope and isherein shown as interfitted therewith,

as at 10. When this magnet is energized by the passing of a suitablecurrent through its coils, the magnetic field established will tend todraw the inserts 5, which in this case may be made of either iron orsteel, and need not have been previously I magnetized, firmly againstthe under side of the cope, as shown.

This magnetic action will also serve to clamp the cope 2 firmly againstthe pole plate 9 of n the magnet, in case the cope is made ofmagnetizable metal. And in case the entire mold is made of such metal,the magnetic action will further serve to clamp the cope and dragtogether so thatno mechanical clamping device will be necessary. In suchcase,

also, the electromagnet may be used in connection with a crane to liftthe cope prior to placing it on the drag, or to lift the entire moldwhen the cope is in place on the drag, a lifting hook 11 being providedin the top of the elect-r'oma-gnet for the purpose. In the completedevelopment of my invention, this making of the entire mold ofmagnetizable metal is contemplated, cast iron lending itself mostperfectly to the purpose. The utilization of electromagnetic action forholding the inserts in place would, however, be possible if the mold orcope were madeiof nonmagnetic metal, or even of nonmetallic material.

In Figs. 1 and 2 the .mold is shown as arranged to receive the steelback 12, with which brake shoes are. now very frequently manent parts,Ihave,

: recess 14 at either end be made of nonmetallic material, or even ofsand, or it may be made of metal having very poor magnetic qualitiessuch as an alloy to have its lug, and in order to prevent the moltenmetal course, be cast in themold shownin Figs.

is arranged "for the casting of a shoe in provided. This back is shownas formed in' the usual manner with a lug l3 which is Struck up from themetal of the back and which, when the shoe is completed, orms the lug;by which the shoe is attached to thel brake head. A'recess 14 isprovided in the bottom of the mold cavity to receive this from fillingthe lug, a core piece 15 is in-i serted in the cavity lt. This corepiece may,.] of course, be madeof sand and baked in the ordinary manner,but to avoid the necessity for venting the mold at this point and toenable the entire mold to be made of peras a further improvement, shownthis core piece'as itself made of metal and in sections,'so that it maybe readily'slipped, into place and as readily knocked outof thecastingwhen completed. Thev piece is made with enlarged head portions16,-,which occupy the ends of the mold of the lug 13 of the steel back.And these head portions are connected-by smaller neck portions 17 whichtogether serve to fill the lug l3 and prevent the molten metal fromflowing into the lug so as to close it. To enable this core piece to beinserted through the lug, and afterward readily knocked out of thecasting, it is made in sections, as shown in Fig. 4, the plane ofcleavage or separation between the sections. being preferably a diagonalone extending through the neck portion of the sections, as indicated at18 in said figure.

In Figs. 5 and 6, I have, illustrated the mold as made up with asomewhat modified electromagnetic arrangement, in which a separatemagnet 20' is provided for each of th' inserts'fi. 'Each magnet is hereshown in, orse shoe form with its pole pieces 21- extending throughholes provided in the cope to receive them, jthe idea eing to apply 'theinserts directly to the ends of. the pole pieces. The cope itself inthis case may iron or manganese. A cover plate 22 is in this instanceshownas secured to the hope over the; coils of the magnets 20, and ispro-' vided with aloo or hook 23 by which the cope is lifted. steel backshoe may, of

5 and 6, as well a s in that shown in Figs. land 2, but asihereinillustrated, the mold which the steel back is omitted, and suchas isillustrated in Fig. 7 In such shoe, the In 13 at its back will be castwith the rest of the shoe, and is here shown as arranged opening 13formed by a core piece 15. This" is illustrated in perspective in Fig.8, and is substantially similar to the core piece shown in. Fig. 4,which I have metal into the mold, and

and harden about the inserts thus held, substantially as described.

already described, the devices 1. The method of making castingscontaining inserts of magnetizable. metal, which consists in holding theinserts in place in the mold by magnetic action, pouring the moltenallowing it to cool 2. The method of making castings containinginsertsof magnetizable metal, which consists insupporting the inserts inthe mold against the attraction of gravitation by magnetic action,pouring the molten metal into the mold, and malntaining the magneticaction until the molten metal has solidified suificiently' to maintainthe inserts in place, substantially as described.

3. The method of making castings containing inserts of magnetizablemetal in a mold of magnetic material which consistsin magnetizingtheinserts, placing the magnetlzing inserts in proper positlon against theinterior surface of the metal mold to be retained there by theirmagnetic action, and, pouring the molten metal into the mold to lnclosethe inserts, substantially as described. 4;.The method of makingcastings containing inserts of magnetizable metal in a mold ofmagnetic'material, which consists in magnetizin either element, placingthem in contact wit eachother so as to be held in place by magneticattraction, and pouring the molten metal into the mold around theinserts thus held, substantially as described. 5. The method of makingcastings which consists in clamping the parts of the mold together bymagnetic action, pouring the moltenmetal into the mold, and maintainingthe magnetic action until themolten metal has solidified, substantiallyas described. 6. The method of making castings containing inserts ofmagnetizable metal in a mold of magnetiza-ble metal, which consists inmagnetizing the mold so as to hold the inserts in position therein bymagnetic attraction, filling the mold with molten metal and allowing itto cool and harden about the inserts thus held, substantially asdescribed.

'7. The method of making castings in a mold of magnetizable metal, whichconsists in magnetizing the mold so as to clamp its parts together bymagnetic attraction, pourmg the molten metal in the moldv and con- Itinuing the magnetic action until the poured I metal has cooled andhardened sulhciently metal, which consists in magnetlzin to maintain itsshape, substantially as described.

8. The method of making castings containing inserts in a mold of maetizablle t e mold so as to hold the inserts therein by magneticattraction and so as to cause the sections of the mold to be clampedtogether by a magnetic attraction, filling the mold with molten metaland maintaining the magnetic action until the entering metalhas cooledand hardened sufliciently to maintain its shape and hold the inserts inplace, substantially as described.

9. The combination with a mold, of an electromagnet for holding insertsof magnetizable metal in position within the mold, preparatory to andduring the casting operation, substantially as described,

10. lhe combination with a mold, and means for inducing a magnet fieldthrough the mold and thereby magnetically holding in osition within themold inserts of magnetizable metal preparatory to and during ee'aoae thecasting operation, substantially as described.

11. The combination with a sectional mold, of means for clamping thesections of the mold together by magnetic attraction preparatory to andduring the casting operation, substantially as described.

12. The method of making castings containing inserts of magnetizablemetal, which consists in placing the, inserts within the .mold, holdingthem in position therein by subjecting them to the'attraction of a mag-Witnesses:

HENRI WAITE, JENNIE L. Fisnn.

CHARLES E. CARTER. v

